TOY181 Tech Install
2018-07-26
: Sonnax Toy181-Tech-Install TOY181-Tech-Install 4170 instructions part uploads
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R E M ANUFAC T UR E D VA LVE BO DIES Te c h & I n s t a l l T i p s U151E, U151F, U250E Remanufactured Valve Body (’04–’16) Part Nos. TOY181 TOY181-RMN Valve Body Installation Tips 1. V erify Case Accumulator Pistons & Springs are Installed Correctly Common spring colors: • C2 (Closest to bell housing) = Yellow U151 Solenoid ID • C3 (Middle) = Plain/No color • B3 (Rear) = Purple (both inner and outer) S4 3. Install Valve Body onto Case a. Install drain back checkball and spring into case, spring first (Figure 2). b. Verify B1 and B2 apply seals are in the case locations. c. Align slot in manual valve with manual linkage. Temperature Sensor Location DSL SL2 2. Air Check While valve body is out, air-check indicated circuits (Figure 2) using low, regulated air pressure. This will help you discover any issues prior to installing the remanufactured valve body. Figure 1 SR SL3 SLT SL1 Common Internal Wire Colors Solenoid Color SL1 White & Black SLT Green & Gray d. A ssemble valve body on case and torque bolts to 11 Nm or 8 ft-lb. SL3 Red & Blue e. Connect wire harness to solenoids and install temperature sensor (Figure 1). Assemble bracket into temperature sensor slot and torque bolt to 6.6 Nm or 58 in-lb. SR Purple S4 Yellow f. Install filter and three retaining bolts and torque to 11 Nm or 8 ft-lb. SL2 Green & Brown g. Assemble pan gasket and pan onto transmission case and torque bolts to 7.8 Nm or 69 in-lb. DSL Light Blue ©2018 Sonnax Transmission Company, Inc. • A Marmon / Berkshire Hathaway Company 866-243-8829 • 856-848-0908 • F: 856-848-1080 • www.sonnax.com TOY181-TECH-INSTALL 07-25-18 Page 1 R E M ANUFAC T UR E D VA LVE BO DIES Te c h & I n s t a l l T i p s U151E, U151F, U250E VALVE BODY TOY181, TOY181-RMN Air Check Locations and Identifiers Valve Body Installation Tips (continued) 4. Fluid Fill & Road Test a. Fill transmission with Toyota WS transmission fluid to factory spec. Figure 2 Lube Pressure b. Let engine run to warm transmission fluid to approximately 175°. Pump Suction TCC Release Pump Pressure Forward Clutch TCC Apply c. Install scan tool to verify transmission fluid temp is achieved. B2 Clutch 1st Reverse NOTE: This function must be done with a capable scan tool. d. Reset transmission memory with capable scan tool. (Battery disconnect will not reset.) C2 Accumulator e. Road test vehicle performing 10–15 upshift and downshift cycles through all five speeds. Drain-Back Check Valve NOTE: A small 2-3 upshift flare or overlap issue, clunk into 4th Gear and a 3-2 downshift clunk is common during adaptive relearn. This condition will typically resolve itself within the 10–15 shift cycles after reset is performed. C3 Accumulator Transmission Diagnostic Tips This remanufactured valve body has been through a rigorous inspection and rebuild process, then a comprehensive, functional hydraulic and electronic test to ensure it meets OE performance and quality. It is designed to eliminate many pressure-, shift- and converter-related complaints, but will not correct complaints that stem from other areas of the transmission. B3 Accumulator C2 Reverse Clutch B1 Clutch 2nd Brake Lube C3 UD Clutch The following are common areas of failure or root causes for symptoms that could be attributed to valve body issues that should also be examined or addressed during your transmission build. A brake and clutch application chart (Figure 3) is below for additional aid in diagnosing problems. B3 UD Brake Clutch C0 Direct Clutch Shift quality complaints can also be caused by: • Clutch and brake clearance issues • 5-4 Downshift clunk can be caused by C1 clutch piston debonding. • Low battery voltage and poor battery grounds • Bushing/bearing failure and overheat can be caused by case bearings turning, evidenced by bits of aluminum debris in ATF. • 2-3 Upshift flare and or binding can be caused by sealing ring problems in the rear cover. NOTE: The case bearing has been known to spin out on high mileage units, causing fine metal to build up which can hang up solenoids and valve trains in the valve body. • This can cause premature C0 clutch failure. A bind-up during 2-3 upshift can be caused by bad speed sensors. Clutch & Brake Application Chart Gear Range FWD Clutch C1 REV Input Clutch C2 Figure 3 Direct Clutch C0 U/D Clutch C3 2nd Brake B1 L/R Brake B2 U/D Brake B3 ON ON Park ON Neutral ON ON ON ON D-2 Gear ON D-3rd Gear ON nd No. 2 One-Way Clutch F2 ON Reverse D-1st Gear No. 1 One-Way Clutch F1 ON ON ON D-4th Gear ON D-5th Gear ON ON ON ©2018 Sonnax Transmission Company, Inc. • A Marmon / Berkshire Hathaway Company 866-243-8829 • 856-848-0908 • F: 856-848-1080 • www.sonnax.com ON ON ON ON ON ON ON TOY181-TECH-INSTALL 07-25-18 Page 2
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